Cushioning elements comprising buckling walls

Abstract

Cushioning elements having a first plurality of parallel buckling walls and a second plurality of parallel buckling walls each comprising an elastomeric material. At least some of the buckling walls of the second plurality intersect and interconnect with at least some of the buckling walls of the first plurality. The elastomeric material comprises an elastomeric polymer and a plasticizer, and a ratio of a weight of the plasticizer to a weight of the elastomeric polymer is from about 0.1 to about 2.2. A height of the cushioning element is at least about 5 inches (12.7 cm). A mattress includes a core structure including buckling walls and a flexible material formed over the core structure.

1 . A cushioning element, comprising:
 a first plurality of parallel buckling walls comprising an elastomeric material; and   a second plurality of parallel buckling walls comprising the elastomeric material, wherein at least some of the buckling walls of the second plurality intersect and interconnect with at least some of the buckling walls of the first plurality;   wherein a height of the cushioning element is at least about 5 inches (12.7 cm), wherein the elastomeric material comprises an elastomeric polymer and a plasticizer, and wherein a ratio of a weight of the plasticizer to a weight of the elastomeric polymer is from about 0.1 to about 2.2.   
     
     
         2 . The cushioning element of  claim 1 , wherein the ratio of the weight of the plasticizer to the weight of the elastomeric polymer is from about 1.5 to about 2.2. 
     
     
         3 . The cushioning element of  claim 1 , wherein a ratio of a distance between adjacent buckling walls of the first plurality to a thickness of the buckling walls of the first plurality is from about 20 to about 60. 
     
     
         4 . The cushioning element of  claim 1 , further comprising at least one stabilizing material secured to at least one end of the first plurality and second plurality of parallel buckling walls. 
     
     
         5 . The cushioning element of  claim 4 , wherein the at least one stabilizing material comprises a first stabilizing material secured to one end of the first plurality and the second plurality of parallel buckling walls and a second stabilizing material secured to an opposite end of the first plurality and the second plurality of parallel buckling walls. 
     
     
         6 . The cushioning element of  claim 5 , wherein the first stabilizing material comprises a stretchable material and the second stabilizing material comprises a limited-stretch material or a non-stretchable material. 
     
     
         7 . The cushioning element of  claim 5 , further comprising a foam material secured to at least one of the first stabilizing material and the second stabilizing material. 
     
     
         8 . The cushioning element of  claim 4 , wherein the at least one stabilizing material is heat-fused to the buckling walls. 
     
     
         9 . The cushioning element of  claim 4 , wherein the at least one stabilizing material is permeable, and wherein a portion of the elastomeric material is disposed within the stabilizing material. 
     
     
         10 . The cushioning element of  claim 9 , wherein the stabilizing material comprises a fabric. 
     
     
         11 . The cushioning element of  claim 9 , wherein the stabilizing material comprises a nylon or polyester fabric. 
     
     
         12 . The cushioning element of  claim 1 , wherein the cushioning element has an overall density from about 3.6 lb/ft 3  (57.7 kg/m 3 ) to about 12 lb/ft 3  (192.2 kg/m 3 ). 
     
     
         13 . The cushioning element of  claim 1 , further comprising a third plurality of buckling walls having a height smaller than a height of the first plurality of parallel buckling walls and the second plurality of parallel buckling walls, the buckling walls of the third plurality interconnected to and interbonded with the parallel buckling walls of the first plurality and the second plurality. 
     
     
         14 . The cushioning element of  claim 1 , wherein each buckling wall of the first plurality is spaced at least about 1.5 inches (3.8 cm) from an adjacent buckling wall of the first plurality, and each buckling wall of the second plurality is spaced at least about 1.5 inches (3.8 cm) from an adjacent buckling wall of the second plurality. 
     
     
         15 . The cushioning element of  claim 1 , wherein the elastomeric material further comprises a plurality of microspheres. 
     
     
         16 . The cushioning element of  claim 14 , wherein the plurality of microspheres comprises a plurality of hollow microspheres. 
     
     
         17 . The cushioning element of  claim 1 , wherein the elastomeric polymer comprises an A-B-A triblock copolymer. 
     
     
         18 . A mattress, comprising:
 a core structure, comprising:
 a first plurality of parallel buckling walls comprising an elastomeric material; and 
 a second plurality of parallel buckling walls comprising the elastomeric material, wherein at least some of the buckling walls of the second plurality intersect and interconnect with at least some of the buckling walls of the first plurality; 
 wherein a height of the core structure is at least about 5 inches (12.7 cm), wherein the elastomeric material comprises an elastomeric polymer and a plasticizer, and wherein a ratio of a weight of the plasticizer to a weight of the elastomeric polymer is from about 0.1 to about 2.2; and 
   a flexible material disposed over the core structure.   
     
     
         19 . The mattress of  claim 18 , further comprising at least one stabilizing material secured to at least one end of the first plurality and second plurality of parallel buckling walls. 
     
     
         20 . The mattress of  claim 18 , further comprising a foam border around a perimeter of the core structure. 
     
     
         21 . The mattress of  claim 18 , wherein the core structure has at least one outside dimension of at least about 54 inches (137.2 cm). 
     
     
         22 . A cushioning element, comprising:
 a first plurality of parallel buckling walls comprising an elastomeric material;   a second plurality of parallel buckling walls comprising the elastomeric material, wherein at least some of the buckling walls of the second plurality intersect and interconnect with at least some of the buckling walls of the first plurality;   a plurality of parallel support members comprising the elastomeric material, wherein at least some of the support members intersect and interconnect with at least some of the buckling walls;   a first stabilizing material secured to a first end of the first plurality and second plurality of parallel buckling walls; and   a second stabilizing material secured to a second end of the first plurality and second plurality of parallel buckling walls,   wherein the elastomeric material comprises an elastomeric A-B-A triblock copolymer and a plasticizer, and wherein a ratio of a weight of the plasticizer to a weight of the elastomeric A-B-A triblock copolymer is from about 1.5 to about 2.2.   
     
     
         23 . The cushioning element of  claim 22 , wherein the elastomeric material has a density of less than about 56 lb/ft 3  (900 kg/m 3 ).